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Inside the Morgan Factory

Morgan Motor Company takes us behind the scenes on the creation of their coachbuilt cars, following each stage of the process and meeting some of the craftsmen who put these unique cars together. Beginning with the creation of Morgan’s famous hand-built ash frame, which is more like fine cabinetry than anything you’ll find on the floors of most auto builders, we follow the creation of the Morgan through to the end. The car’s chassis design hasn’t changed since the 1930s and the aluminum body panels are each hand finished to ensure a perfect fit.

It’s fascinating that the car’s body is pushed down the alleyway into the neighboring paint shop – sort of like riding the world’s most expensive Razor scooter. After it arrives, it can be painted in one of 40,000 paints or the buyer can have any color they wish matched by Morgan. And even after the paint is completed, the finish is inspected multiple times to ensure there are no imperfections. Finally, the interior upholstery and convertible top are hand-stitched and fitted to the car before the windows are put in place and everything finished for the test drive.

From start to finish, the Morgan takes three weeks to build. I can’t imagine the number of man-hours that goes into each one, but the results speak for themselves. You can visit the Morgan factory in person for a tour; find more information here.